Bistable Electromagnetic Clutch With Zero-Power Holding
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Solution Overview
Problem
Conventional electromagnetic clutches face issues such as unintended disconnection due to power loss, high energy consumption, and heat generation, which affect their performance and service life, particularly in new energy vehicles.
Innovation Solution
A bistable electromagnetic clutch design featuring a yoke with iron cores and electromagnetic coils, a moving carrier disc with magnets, and a spring mechanism that maintains separation or engagement without power consumption, utilizing grouped electromagnetic coils and magnets to form closed magnetic circuits and minimize energy usage.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If conventional electromagnetic clutch is used, then it can transmit torque, but it consumes high energy and generates heat due to continuous power supply requirement
Solution Approach 1:
The clutch mechanism transitions from static continuous engagement to dynamic bistable operation, where the clutch can maintain engagement or disengagement states without continuous power supply. The movable carrier disc can be dynamically positioned in either engaged or disengaged state, and remains stable in that state without energy input.
Solution Approach 2:
The clutch system uses its own magnetic field and spring mechanism to maintain engagement state without external energy input. Once engaged, the magnetic attraction between electromagnet and armature plate, combined with spring force, self-maintains the connected state without requiring continuous power supply.
2Duration of action of stationary object
If conventional electromagnetic clutch operates continuously, then it maintains engagement, but it generates excessive heat affecting service life
Solution Approach 1:
The clutch operates in periodic cycles of engagement and disengagement rather than continuous operation. The electromagnetic coil is energized only temporarily to switch states, then powered off while maintaining engagement through magnetic and spring forces, creating a periodic on-off operation pattern that reduces cumulative heat generation.
Solution Approach 2:
The magnetic field, which would continuously generate heat if maintained, is instead used temporarily to establish engagement, then allowed to decay naturally. The spring force and residual magnetism convert the potential harmful continuous electromagnetic heating into beneficial mechanical holding force.
3Productivity
If electromagnetic coil is affected by current fluctuation, then torque transmission varies, but this leads to high energy consumption
Solution Approach 1:
The system uses the magnetic field strength and spring force as inherent feedback mechanisms to maintain stable engagement. The magnetic attraction force automatically adjusts to maintain contact between the armature plate and electromagnet, providing self-regulating torque transmission without requiring active current control.
Solution Approach 2:
The patent replaces continuous electromagnetic control with a mechanical-bistable system where spring force and magnetic attraction work together to maintain engagement. This substitutes the need for continuous electrical power and current regulation with passive mechanical holding forces.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The bistable design eliminates energy consumption and heat generation in both states, ensuring a fail-safe mechanism, improving reliability and extending service life while reducing magnetic leakage and achieving a compact, lightweight structure.
Implementation Method 1
an electromagnetic coil is provided on each of the iron cores
Implementation Method 2
several magnets are fixed on the moving carrier disc, and the iron cores and the magnets are provided in a correspondence position/location
Implementation Method 3
the spring part is configured to keep the moving carrier disc and the yoke in normally separated positions
Data Source
AI summary
A bistable electromagnetic clutch is provided that includes a first part, a second part and an spring part. The first part includes a yoke with a plurality of iron cores, and an electromagnetic coil on each of the iron cores. The second part includes a moving carrier disc and a magnetic conductive disc that is fixed on a side of the moving carrier disc that is away from the yoke. Several magnets are fixed on the moving carrier disc, and the iron cores and the magnets are provided in a correspondence relation. The spring part is configured to keep the moving carrier disc and the yoke in normally separated positions. Two adjacent electromagnetic coils form a group, two electromagnetic coils in a same group are wound to form a group of windings with identical magnetic polarities, and corresponding two magnets form a group of magnetomotive forces with identical magnetic polarities.